FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [(E)]

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Special Service Tool (SST)

1.  : Mazda SST number 2.  : Global SST number
1: 49 UN31 0123 2: 310–123   wrench		1: 49 JP02 002 2: –   Lock ring wrench

Replacement part

Oil and Chemical Type

Warning

•  Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

•  Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the “Fuel Line Safety Procedure” to prevent the fuel from spraying.

―  Fuel may cause irritation if it comes in contact with skin and eyes.

―  If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.

•  A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before performing work on the fuel system, discharge static electricity by touching the vehicle body.

Caution

•  Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

Fuel Gauge Sender Unit (Main)

SKYACTIV-G, SKYACTIV-X

Note

•  For the fuel gauge sender unit removal/installation, refer to the fuel pump removal/installation because the fuel gauge sender unit is integrated with the fuel pump. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].) (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].) (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

SKYACTIV-D

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 1.8].)

Warning

•  If the fuel gauge level indicates 8/16 or more, refer to the [FUEL DRAINING PROCEDURE] and drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 1.8].)

2.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)

3.  Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

4.  Remove the screws.

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5.  Remove the service hole cover.

6.  Disconnect the connector.

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7.  Move the retainer upward using a small flathead screwdriver or a similar tool.

8.  Pull out the fuel hose straight from the fuel pipe and disconnect it. (SeeQuick release connector assembly note (fuel gauge sender unit (main)).)

9.  Install the SST shown in the figure.

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10.  Remove the set plate component using the SST. (See Set plate component installation note (main).)

11.  Remove the fuel gauge sender unit and packing.

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12.  Install in the reverse order of removal.

13.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 1.8].)

Set plate component installation note (main)

1.  Align the reinforcement part of the set plate component near the pipe area of the fuel pump unit as shown in the figure and assemble.

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Quick release connector assembly note (fuel gauge sender unit (main))

Note

•  If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

1.  Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.

•  If there is any malfunction, replace it with a new one.

2.  Install the quick release connector.

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•  Insert the fuel pipe straight to the end of the quick release connector.

•  Push down the retainer using a finger.

―  If the retainer cannot be pushed down, push the fuel pipe further to the quick release connector.

3.  Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

4.  Perform the fuel leakage inspection referring to “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 1.8].)

Fuel Gauge Sender Unit (Sub)

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-X 2.0].)

Warning

•  If the fuel gauge level indicates 8/16 or more, refer to the [FUEL DRAINING PROCEDURE] and drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-X 2.0].)

2.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)

3.  Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

4.  Remove the screws.

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5.  Remove the service hole cover.

6.  Disconnect the connector.

Caution

•  Be careful not to damage the fuel pipe when unlocking the retainer.

Note

•  If the quick release connector is removed, replace the retainer with a new one.

7.  Set the finger parallel to the quick release connector.

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Note

•  The quick release connector can be removed by pushing the center of the retainer tabs.

•  The retainer is attached to the fuel pipe even after the connector is disconnected.

8.  Hold the center of the retainer tabs with the finger and press the retainer.

9.  Pull the connector side and disconnect the quick release connector.(See Quick release connector assembly note (fuel gauge sender unit (sub)).)

10.  Install the SST shown in the figure.

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11.  Remove the set plate component using the SST. (See Set plate component installation note (fuel gauge sender unit (sub)).)

12.  Remove the fuel gauge sender unit and packing.

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13.  Install in the reverse order of removal.

14.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-X 2.0].)

Set plate component installation note (fuel gauge sender unit (sub))

1.  Align the reinforcement part of the set plate component near the pipe area of the fuel pump unit as shown in the figure and assemble.

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Quick release connector assembly note (fuel gauge sender unit (sub))

Note

•  If the quick release connector O-ring is damaged or has slipped, replace the piping component.

•  A checker tab is integrated with the quick release connector for new fuel hoses and fuel hoses. Remove the checker tab from the quick release connector after the connector is completely engaged with the fuel pipe.

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1.  Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.

•  If there is any malfunction, replace it with a new one.

2.  Apply a small amount of clean engine oil to the sealing surface of the fuel pipe.

3.  Install a new retainer to the quick release connector.

4.  Reconnect the fuel hose straight to the fuel pipe until a click is heard.

5.  Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.